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D O C U M E N TA Z I O N E T E C N I C A



USER’S MANUAL



138.11.A01_00 PISTON PUMPS FOR CERAMIC SLIP



PPB 308 - PPB 313



TECHNICAL DOCUMENTATION DOCUMENTATION TECHNIQUE TECHNISCHE DOKUMENTATION DOCUMENTACION



TECNICA



DOCUMENTAÇAO



TÉCNICA



ISH



L ENG



138.11.A01 INDICE OF CONTENTS TABLE



0-2



Revision 00 Date 04.10.1999



Revision 00 Date 04.10.1999



138.11.A01 TABLE OF CONTENTS



USER’S MANUAL



PISTON PUMPS FOR CERAMIC SLIP



PPB 308 - PPB 313



MANUFACTURER SACMI IMOLA Via Selice Provinciale, 17/A 40026 IMOLA (Bologna) - ITALIA



SERIAL NUMBER



YEAR OF MANUFACTURE



PUBLISHED ON November 9, 1999



REVISION 00



VERSIONS PPB308A - PPB308B - PPB313B



0-3



138.11.A01 INDICE OF CONTENTS TABLE



0-4



Revision 00 Date 04.10.1999



Revision 00 Date 04.10.1999



138.11.A01 TABLE OF CONTENTS



1



Page GENERAL INFORMATION ........................................................................................................................1 - 1 1.1 INTRODUCTION ......................................................................................................................... 1 - 1 1.2 HOW TO KEEP THE MANUAL ....................................................................................................1 - 1 1.3 HOW TO USE THE MANUAL ......................................................................................................1 - 1 1.4 USERS OF THE MANUAL .......................................................................................................... 1 - 1 1.5 WARRANTY ................................................................................................................................ 1 - 2 1.6 SUPPLEMENTS ...........................................................................................................................1 - 2 1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL ............................................................................................................................. 1 - 2 1.8 MACHINE IDENTIFICATION PLATE .......................................................................................... 1 - 3



2



MAIN FEATURES ......................................................................................................................................2 - 1 2.1 DESCRIPTION OF THE EQUIPMENT ........................................................................................2 - 1 2.1.1 MAIN ASSEMBLIES .................................................................................................................... 2 - 2 2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ...................................................2 - 5 2.2 OVERALL DIMENSIONS .............................................................................................................2 - 6 2.3 TECHNICAL DATA ......................................................................................................................2 - 7 2.3.1 SPECIFICATIONS ...................................................................................................................... 2 - 7 2.3.2 NOISE LEVELS ........................................................................................................................... 2 - 8 2.3.3 LUBRICANT SPECIFICATIONS ................................................................................................. 2 - 9 2.4 DIAGRAMS ............................................................................................................................... 2 - 10 2.4.1 SPRAY DRYER SLIP SUPPLY SYSTEM ................................................................................. 2 - 10 2.4.2 HYDRAULIC SCHEMATIC ....................................................................................................... 2 - 11 2.4.3 POINTS OF USE (INSTALLATION DIAGRAM) ...................................................................... 2 - 12 2.4.4 WIRING BOX 1, HYDRAULIC POWER UNIT .......................................................................... 2 - 13 2.4.5 WIRING BOX 2, PUMP ............................................................................................................. 2 - 13



3



SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1 3.1 PROTECTION AND SAFETY DEVICES INSTALLED ............................................................... 3 - 1 3.2 GENERAL SAFETY RULES ........................................................................................................3 - 3 3.3 HANDLING PROCEDURES ........................................................................................................3 - 4 3.4 OPERATOR TRAINING ...............................................................................................................3 - 5 SAFETY RULES TO BE OBSERVED WHEN OPERATING AND SERVICING THE MACHINE ....... 3 - 6 3.5 3.5.1 HAZARDS DERIVING FROM MECHANICAL PARTS ............................................................... 3 - 7 3.5.2 HAZARDS THAT MAY BE ENCOUNTERED IN THE ELECTRICAL SYSTEM ........................ 3 - 7 3.5.3 MAINTENANCE ...........................................................................................................................3 - 8 3.6 MAKING THE MACHINE INOPERATIVE ................................................................................... 3 - 9



4



INSTALLATION ........................................................................................................................................ 4 - 1 4.1 LIFTING AND HANDLING .......................................................................................................... 4 - 1 4.2 POSITIONING AND CONNECTING THE PUMP ........................................................................4 - 3



5



START UP ..................................................................................................................................................5 - 1 5.1 GENERAL INFORMATION ......................................................................................................... 5 - 1 5.2 PRELIMINARY CHECKS .............................................................................................................5 - 1



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138.11.A01



Revision 00 Date 04.10.1999



INDICE OF CONTENTS TABLE



6



OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1 6.1 CONTROL DEVICES .................................................................................................................. 6 - 1 6.2 STARTING AND STOPPING THE EQUIPMENT ........................................................................6 - 1 6.2.1 START UP PROCEDURE ........................................................................................................... 6 - 1 6.2.2 STOPPING THE MACHINE ........................................................................................................ 6 - 2 6.3 OPERATION ............................................................................................................................... 6 - 2 6.4 TIMING ........................................................................................................................................ 6 - 4 6.5 FIRST-TIME START UP ............................................................................................................. 6 - 6



7



ADJUSTMENTS ........................................................................................................................................ 7 - 1 7.1 MACHINE ADJUSTMENTS DURING OPERATION ...................................................................7 - 1



8



MAINTENANCE OPERATIONS ............................................................................................................... 8 - 1 8.1 SCHEDULED MAINTENANCE ....................................................................................................8 - 2 8.2 SPECIAL MAINTENANCE .......................................................................................................... 8 - 8 8.3 CHECKING THE NUTS AND BOLTS FOR TIGHTNESS ........................................................ 8 - 10



9



DECOMMISSIONING ................................................................................................................................ 9 - 1



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138.11.A01



GENERAL INFORMATION 1



GENERAL INFORMATION



1.1



INTRODUCTION



E0004P



1



WARNING!



Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts. This manual contains important information for safeguarding the operators, the maintenance staff as well as the machine itself. Sacmi reserves the right to make changes to the machine and in the manual without giving prior notice. Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI. The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied, reproduced, disclosed or transferred. Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.



1.2



E0004P



HOW TO KEEP THE MANUAL



WARNING!



This manual is supplied with the machine and must be kept along with it even if it is resold. Always keep the manual near the machine where it can be easily consulted. The manual must always be close at hand so that the operator and maintenance staff are able to consult it rapidly at any time.



1.3



HOW TO USE THE MANUAL



The lay-out of this manual allows it to be easily consulted as all the information and instructions provided are grouped together and divided into chapters and paragraphs. The user has to simply refer to the table of contents. The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and are written in italics, as shown below.



E0004P



WARNING!



Chapter 3, SAFETY EQUIPMENT AND PRECAUTIONS, must be carefully read in its entirety as it contains important information and warnings regarding safety.



1.4



USERS OF THE MANUAL



In this manual the machine operators are categorized as follows: - Operator: this is the person responsible for supervising and operating the machine. - Routine maintenance men. For a more detailed description, see paragraph 3.4 - OPERATOR TRAINING in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS. 1-1



138.11.A01 1 1.5



Revision 00 Date 04.10.1999



GENERAL INFORMATION WARRANTY



SACMI shall be held responsible only for the machine as it was at the time of delivery. Any modifications to the machine or work cycle must be carried out by SACMI personnel or duly authorized by SACMI’s Engineering Dept. SACMI shall not be held responsible for damage deriving from the use of non-original spare parts.



E0004P



WARNING!



The operators or maintenance staff should not carry out any operations, special maintenance or repairs when the machine is under warranty. These procedures are to be performed only by the manufacturer’s specially trained personnel. For this reason, these types of operations are not dealt with in this manual.



1.6



SUPPLEMENTS



- None



1.7



LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE MANUAL



DANGER SYMBOLS



General hazard E0004P



E0003P



Danger of hands being injured



High voltage, risk of electric shock E0007P



ALERT SYMBOLS



Machine must be connected to efficient ground electrodes. E0006O



1-2



138.11.A01



Revision 00 Date 04.10.1999



GENERAL INFORMATION 1.8



1



MACHINE IDENTIFICATION PLATE



TIPO TYPE MATRICOLA No. SE R I A L N U M B E R ANNO YE A R



VIA



SELICE



PROVINCIALE



17/A



IMOLA



-



I TA L I A



E0020 C1632



1-3



138.11.A01 1



1-4



Revision 00 Date 04.10.1999



GENERAL INFORMATION



Revision 00 Date 04.10.1999



138.11.A01 MAIN FEATURES



2



MAIN FEATURES



2.1



DESCRIPTION OF THE EQUIPMENT



2



The piston pump is engineered and constructed to deliver ceramic slip to spray dryers. It basically consists of two parts: a piston pump assembly and hydraulic power unit. The function of the pump assembly is to create a flow of liquid and maintain it at the preset delivery rate and pressure required for the system in which the pump is installed. The hydraulic power unit delivers oil at a constant pressure. Thanks to the hoses used, the oil is sent alternately to the cylinders of the piston pump.



Figure 2.1 - OVERALL VIEW 1 Pump assembly 2 Hydraulic power unit



1



2



C1633



2-1



138.11.A01 2 2.1.1



Revision 00 Date 04.10.1999



MAIN FEATURES MAIN ASSEMBLIES



2.1.1.1 Piston pump assembly (references given in figure 2.1.1.1) The pump assembly basically consists of two alumina pistons (1), which are driven by the hydraulic cylinders (2) and alternately immersed in the pump casings (3), thus creating a consistent flow of liquid. The intake valves (4) and delivery valves (5) control the flow rate. In addition, the accumulator (7), located on the manifold (6), reduces any changes in pressure which may take place when the pistons reverse. The seals (8), pre-loaded by the device (9), are located between the pistons and the pump casing. A small slide (11), provided with lubricated bushes which move along chrome-plated steel guides, ensure the piston moves properly during pump operation. Two lines (10) are connected to hydraulic cylinders. They ensure the alumina pistons perform their reciprocating motion in a synchronised manner. Alumina, which is particularly wear resistant, was opted for as dense fluids (especially ceramic slip) are highly abrasive on the moving parts. In order to reduce wear, clean water should be put in the top of the pump casing near the ring nut (9). Creating a flow over the seals, the water “lubricates” them, thereby reducing friction while at the same time washing the piston and eliminating any abrasive liquid which may have leaked out. Guards (12) are provided for protection against the moving parts, thus safeguarding the operating personnel. The reverse sensors (14) and timing sensors (15) are found on the guard mounts (13). The sensors are protected by the removable covers (16). This particular set up allows the position of the sensors to be changed without having to take off the guards (12). In this way, the operator can safely adjust the piston stroke while the machine is running.



2-2



138.11.A01



Revision 00 Date 04.10.1999



MAIN FEATURES



2



Figure 2.1.1.1 - PISTON PUMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16



Alumina pistons Hydraulic cylinders Pump casing Intake valve (plate-type) Delivery valve (plate-type) Manifold Accumulator Seals STD tie-rod system Hydraulic lines (upstroke and timing) Piston slide Guards Mounts Reverse sensors Timing sensors Removable covers



7 10



11 15



2



13 12



14



9 8 3 4



16 15 6



5 1 C1636



2-3



138.11.A01 2



Revision 00 Date 04.10.1999



MAIN FEATURES



2.1.1.2 Hydraulic power unit (references given in figure 2.1.1.2) The hydraulic power unit comes with a sheet metal reservoir (1). Along with the oil required for proper system operation, a tube-bundle heat exchanger (2) is found inside the reservoir. The exchanger is connected to the water supply system. The motor-and-pump unit (3), oil thermostat (4), filler (5), suction filter (6), drain filter (8) and a hydraulic assembly (7) for controlling the pressure and cylinder reverse motion are found on the reservoir.



Figure 2.1.1.2 - HYDRAULIC POWER UNIT 1 2 3 4 5 6 7 8



Reservoir Heat exchanger Motor-and-pump unit Oil thermostat Filler Suction filter Hydraulic control assembly Drain filter



3 7



5



4



8



1



6



C1637



2 2-4



Revision 00 Date 04.10.1999



138.11.A01 MAIN FEATURES



2.1.2



2



INTENDED, PROHIBITED AND MISUSE OF THE MACHINE



INTENDED USE OF THE MACHINE The machine is specially engineered and constructed to produce products that have the characteristics indicated in the specifications (see paragraph 2.3.1 - SPECIFICATIONS). Safe machine operation is ensured only if the following conditions are satisfied: - the machine is used under the required conditions and within the preset limits; - maintenance is regularly carried out as specified in chapter 8 - MAINTENANCE; - the machine is used correctly as directed in chapter 6 - OPERATING INSTRUCTIONS



E0004P



WARNING!



The pump is part of a spray drying plant and is therefore operated remotely from the spray dryer’s control panel. It cycles together with the spray dryer.



UNINTENDED AND PROHIBITED OPERATIONS No other tasks except those specified by the Manufacturer are to be performed. For this reason, the Manufacturer shall not be held responsible for the consequences deriving from failure to observe the instructions contained herein. MISUSE OF ERRONEOUS USE The Manufacturer shall not be held responsible for the consequences deriving from improper use of the equipment. These consequences may be the result of: - use of the pump by unqualified personnel; - fatigue (in particular during night shifts) or carelessness; - negligence caused by superficiality or wrong habits The equipment must be operated by well trained personnel capable of: - using it correctly in normal working conditions; - and, above all, facing emergencies.



2-5



138.11.A01 2 2.2



Revision 00 Date 04.10.1999



MAIN FEATURES OVERALL DIMENSIONS



207



577



1672



1107 PPB308 - 1214 PPB313



Figure 2.2 - OVERALL DIMENSIONS



950 1840



659



659 1363



750



560



= =



600



= =



1000



= =



1050



= =



700



520 = =



585 = =



2-6



C1638



138.11.A01



Revision 00 Date 04.10.1999



MAIN FEATURES 2.3



TECHNICAL DATA



2.3.1



SPECIFICATIONS



Maximum head with material having a specific weight of 1.7 kg/dm



3



Maximum flow rate of fluid to be transferred Maximum pressure of fluid to be transferred Operating pressure range Power requirements (at 50 Hz) Cooling water at 20° C flow rate Oil in hydraulic power unit Hydraulic unit reservoir (capacity) Hydraulic unit pump (delivery rate) (maximum pressure) (operating pressure) Weight hydraulic power unit (no oil) pump Oil accumulator inflating pressure Slip accumulator inflating pressure (pre-charge)* Minimum pressure for cooling water



m l/h bar bar kW l/1' l l l/min bar bar kg kg bar bar atm



2



PPB308



PPB313



3.5 8000 30 5 - 30 15 20 150 160 75 80 75 350 1000 50 13 - 15 2



3.5 13000 30 5 - 30 22 20 150 160 85 115 110 350 1000 70 13 - 15 2



* Only for precharged accumulators (OPT)



2-7



138.11.A01 2



Revision 00 Date 04.10.1999



MAIN FEATURES



2.3.2



NOISE LEVELS



Test conditions - Operating conditions (refer to ISO/DIS 11202 standard, point 9.5) - Type of operation: - fluid pumping - Work cycle: - pumping (refer to ISO/DIS 11202 standard, point 3.11) - Test conditions: - hydraulic unit pressure (bar) 100 - operating pressure (bar) 30 - flow rate 11 m3/h - Test environment in a factory Instruments employed Class 1 instruments (IEC 804) Acoustic radiation pressure (ISO/DIS 11202) Noise emission level (ISO 3746) Measurements LbA Background noise level (dB A) LpA Acoustic radiation pressure emitted, corrected, weighed A, average over time (dB A) LwA Noise emission level in dB, weighed A (dBA)



P1 P1



41.3 81 92



Figure 2.3.2 - PLACE WHERE NOISE LEVEL WAS RECORDED P1 . d



Noisiest point of the area where measurements were taken Area where noise level was measured Datum zone P1 =1m



d



C1639



2-8



Revision 00 Date 04.10.1999



138.11.A01 MAIN FEATURES



2.3.3



2



LUBRICANT SPECIFICATIONS



HYDRAULIC POWER UNIT



SLIDE BUSHES



OIL



HYDRAULIC OIL ISO VG46



GREASE



Dropping point 180° C Penetration 350/370 dmm



2-9



138.11.A01 2



Revision 00 Date 04.10.1999



MAIN FEATURES



2.4



DIAGRAMS



2.4.1



SPRAY DRYER SLIP SUPPLY SYSTEM



Figure 2.4.1 - SLIP SUPPLY SYSTEM 1 2 3 4 5 6 7 8



Suction line Pump Delivery line Slip filters Spray dryer supply line Nozzle holder Drying unit Hydraulic unit pump



6 3 8



5 7



2 1



4



C1389



2 - 10



138.11.A01



Revision 00 Date 04.10.1999



MAIN FEATURES 2.4.2



2



HYDRAULIC SCHEMATIC



Figure 2.4.2 - HYDRAULIC SCHEMATIC 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16



Check valve Cock and pressure gauge Pressure gauge Accumulator Reversing valve Reversing throttles Pilot solenoid valve YV3 - YV4 Filter element Pressure control valve Pressure relief valve Electric motor Coupling Vane pump Check valve Suction filter



17 18 19 20 21 22 23 24



Drain filter Reservoir Cooler Level indicator Thermometer and switch Hydraulic cylinders Timing valve YV1 Solenoid valve YV2, Upstroke chamber loading SQ Sensors Hydraulic circuit Pilot circuits



23 YV1 A



B



YV2



22



22 24



SQ1



SQ4



A



B



P



T



7



SQ2



SQ3



6



7 A



B



YV4 P



T



8



5 3



YV3



2 1 P T



12



13



14



9



21 10



11



20 19



15 16



17



H2O



18 C0867



2 - 11



138.11.A01 2



Revision 00 Date 04.10.1999



MAIN FEATURES



2.4.3



POINTS OF USE (INSTALLATION DIAGRAM)



Figure 2.4.3 - POINTS OF USE (INSTALLATION DIAGRAM) 1 Electrical box, Hydraulic power unit 2 Electrical box, Pump 3 Hydraulic unit control ass’y 4 Pump cylinders 5 Delivery line 6 Intake line A-B Connecting hoses HD30 Inlet and outlet fittings, hydraulic unit cooling water HD31 Piston washing water connection 3



B



A 5 HD31



HD31



2 B 4



A



1 HD30



6 2 - 12



C1640



138.11.A01



Revision 00 Date 04.10.1999



MAIN FEATURES 2.4.4



2



WIRING BOX 1, HYDRAULIC POWER UNIT



M ST3



YV4



YV3



SC.2



2



XT1 XT2



901



303



900



1



2 2 2 303 304 305 306



1



1 24 24 101 102 103 104



SC.2



24 24 101 102 103 104 2



2x1,5 (2 - 1) 2x1 (900 - 901)



24 2 101 102 103 104 303 304 R1



304



ST3 N.C 900 - 901



305 306



PPB 130 - 85 - 900



2



YV4 2 - 306



2 1 1



YV3 2 - 305



C1641



WIRING BOX 2, PUMP



YV1



YV2



2



SQ1



SQ4



SQ2



SQ3



YV1 2 - 303



SQ1



303 304



YV2 2 - 304



2 2 24 24 101 102 103 104



2.4.5



24 101



24 104



2



SQ2



24 102 2



SQ4



2 24 103 K21



SQ3



2



C0870



2 - 13



138.11.A01 2



2 - 14



MAIN FEATURES



Revision 00 Date 04.10.1999



Revision 00 Date 04.10.1999



138.11.A01



SAFETY EQUIPMENT AND PRECAUTIONS 3



SAFETY EQUIPMENT AND PRECAUTIONS



3.1



PROTECTION AND SAFETY DEVICES INSTALLED



3



(See figure 3.1) The machine is provided with a number of protection and safety devices which safeguard the operator and the machine. Shutdown devices These devices (oil thermostat in hydraulic power unit) detect malfunctioning and prevent the machine from being started or stop it if running. Stoppage The operator is informed by the spray dryer control system whenever a stoppage occurs. Equipment which safeguards the operator EMERGENCY STOP BUTTON An emergency stop button is located on the spray dryer control panel. When pressed, the spray dryer, ventilation and fuel supply systems are immediately shut off. Reset from the control panel. FIXED PISTON GUARDS The operator may be injured or caught in the zone where the alumina pistons operate. To prevent access to these potentially hazardous zones, the pump (1) is provided with fixed guards that cannot be removed without using specific tools and do not stay in place if fasteners are not provided. Slots are found at the bottom of the guards, they are used to pass the wrenches through when seals need to be removed and are provided with covers. The latter are to be pulled off when adjustments are to be made by well-trained personnel.



E0004P



WARNING!



Only the wrenches supplied with the machine can be pushed through the slots in the fixed guards. Keep your hands or any objects away from the slots.



INTAKE VALVE COVERS The covers (2) that protect the intake and delivery valves prevent the closure plates from coming out if they are not in place. SENSOR COVERS The removable covers (3) are installed on the sides of the machine. These covers protect the reverse and timing sensors from being banged or accidentally moved. PRESSURE RELIEF VALVE The hydraulic system comes with a pressure relief valve (4). This valve is found in the hydraulic control assembly and is set to the maximum allowable pressure. This is done to guarantee top machine performance and prevent the system from exceeding the set value, thus avoiding malfunctions.



3-1



138.11.A01 3



Revision 00 Date 04.10.1999



SAFETY EQUIPMENT AND PRECAUTIONS



Figure 3.1 - PROTECTION AND SAFETY DEVICES INSTALLED 1 2 3 4 5



Pump guard Valve cover Sensor cover Pressure relief valve Oil thermostat



1



3 2



5



4



C1633



3-2



Revision 00 Date 04.10.1999



138.11.A01



SAFETY EQUIPMENT AND PRECAUTIONS 3.2



E0004P



3



GENERAL SAFETY RULES



WARNING!



INSTALLATION Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations in force in your country. It is extremely important that the machine is properly connected to adequate earth electrodes. SACMI shall not be held responsible for any damage to the machine or injury to personnel resulting from improper installation. SAFETY DEVICES & GUARDS The machine comes equipped with electrical and/or mechanical safety devices which safeguard the machine and the operator. The safety devices and guards provided MUST NOT be removed or inactivated under any circumstances. SACMI shall not be liable for any damage or injury if the machine operator fails to observe these precautions. The machine cannot be started up if the safety devices are not operative. Periodically check all the safety devices (emergency stop button, interlocks, limit switches, barrier guards, etc..) installed to see that they are efficient. CHECKS, REPAIRS & MAINTENANCE Do not perform any checks, repairs or maintenance operations on moving parts. Use clearly visible signs to warn all personnel of possible danger. Before carrying out these operations, shut off the electricity supply by using the main switch. The main switch is to be padlocked in the “power off” position so that the machine cannot be started up accidentally. To ensure overall machine efficiency and trouble-free operation, it is essential that the directions supplied by SACMI are followed and that the required maintenance is carried out. It is advisable to periodically check all of the safety devices for proper functioning and the insulation of the electrical cables. The latter must be replaced if damaged. LIVE ELECTRICAL PARTS It is severely forbidden to work on or near live electrical parts. The electrical cabinet doors must be kept locked and warning signs signalling potential danger must be placed on them Before opening the electrical cabinets or switchboards, shut off the electricity supply with the main switch. Periodically check that the ground is effective. QUALIFIED PERSONNEL The assembling, disassembling and servicing of the machine must be performed by qualified personnel. When carrying out these operations, always use adequate equipment and follow the instructions provided. MACHINE NO LONGER USED If the machine is no longer going to be used, make it inoperative by unplugging the power cable from the supply mains. Install any required safety devices.



3-3



138.11.A01 3 3.3



E0004P



Revision 00 Date 04.10.1999



SAFETY EQUIPMENT AND PRECAUTIONS HANDLING PROCEDURES



WARNING!



SLINGING THE LOAD To safely lift the machine, always follow the directions below : - Use adequate lifting equipment. (Note that the weight is indicated on the crates and packing containers as well as printed in the relevant form written in the customer’s own language). - Cover all sharp edges. - Check the safety device the hook is provided with. Before lifting: - Make sure all personnel are away from the machine. - Make sure the load does not sway. - Make sure all parts which may fall are secured in position. - Lift the machine vertically in order to prevent collision with anything placed nearby HANDLING The load should always be lifted and handled with the aid of sticks, levers and grapples. Never use your hands! The person in charge of handling and lifting must always: - Know where the machine is to be carried. - Instruct the crane operator from a visible position. - Stop the operations if hazardous situations occur. - Keep bystanders away from overhead loads. PLACING THE LOAD Before the load is placed in position, make sure the floor is level and strong enough. Never place loads near exits, fire fighting equipment, passageways, control panels or power lines . The load is to be placed on suitable supports in order to keep it stable and help the personnel remove the sling. Never place containers in bad condition with protruding parts on top of each other. Never stack parts to a height which may affect stability. INSTALLATION If the machine is installed by the customer’s personnel, the instructions provided by the manufacturer and current safety regulations are to be followed. Always connect the machine to adequate ground electrodes. Improper installation may result in severe injury to personnel and damage to equipment. The manufacturer declines all responsibility. The manufacturer shall not be held responsible for unsafe machine operation if some parts are provided and installed by the customer.



3-4



Revision 00 Date 04.10.1999



138.11.A01



SAFETY EQUIPMENT AND PRECAUTIONS 3.4



E0004P



3



OPERATOR TRAINING



WARNING!



The factory supervisor should see that the machine operators: - meet the requirements listed below; - have fully understood the instructions contained in the manual; - are well trained on how to safely carry out their tasks; - have received specific instructions on how to operate the machine correctly. The machine operators should: - understand the instructions provided and have specific experience in operating this type of machine - be sufficiently educated so as to be able to read and fully understand the contents of this manual as well as the drawings provided - have a good technical background (in the electric, mechanical and pneumatic fields) so that they are able to safely carry out the jobs they are responsible for as specified in the manual - know all the safety rules and regulations in force in the country where the machine is installed i.e.: - general rules (regarding hygiene and on-the-job safety as well as work accident prevention) - specific rules (for the type of product being manufactured) The maintenance staff should be employed on the basis of the same criteria. In addition, they must be qualified in specific technical fields (mechanical, electric, and pneumatic) so that they can safely carry out the operations they are responsible for (as specified in the manual). Tasks the operator and maintenance staff are and are not responsible for The jobs the personnel are responsible for are dealt with in various parts of this manual (i.e. machine operation, routine maintenance, special maintenance, etc...). It is fundamental that the personnel only carry out the tasks they are specifically responsible for (mechanical, electric, and pneumatic).



3-5



138.11.A01 3 3.5



Revision 00 Date 04.10.1999



SAFETY EQUIPMENT AND PRECAUTIONS SAFETY RULES TO BE OBSERVED WHEN OPERATING AND SERVICING THE MACHINE



The aim of this chapter is to inform the operators and maintenance staff: - about some potentially hazardous and/or dangerous situations that may be encountered while operating or performing maintenance on the machine - about the safety measures and devices employed and how to use them correctly - about any additional risks - on the measures to be taken (general and specific precautions to eliminate potentially harmful situations). Detailed information is given in this chapter. Your attention is called to the instructions in this manual, at the points where the situations are encountered.



E0004P



WARNING!



For added clarity, some illustrations in the manual show the machine or parts of it without guards or with the guards removed. Do not operate the machine if the safety guards and devices have been removed or inactivated. In addition to satisfying the requirements stated above the operator and maintenance staff must attend a training course and receive on-the-job instructions before working on the machine. Along with receiving information on machine operation and maintenance under normal conditions, they should know: - the safety precautions and how to use the various devices, - how to identify, control and face dangerous situations described in this manual and in particular in this chapter.



When operating this machine, the potential hazards more likely to be encountered are in the mechanical, hydraulic and electrical systems. Where possible, hazardous situations have been eliminated: - directly, during the design stage - indirectly, by using barriers, guards and safety devices.



E0004P



WARNING!



Do not operate the machine if the barriers, safety guards and devices have been removed or altered in any way. Before performing any type of operation on the machine, always consult the manual for information on how to correctly carry out the procedures. In addition, the manual contains important information concerning safety. If any doubts arise, contact SACMI’s After-Sales Service Department.



3-6



Revision 00 Date 04.10.1999



138.11.A01



SAFETY EQUIPMENT AND PRECAUTIONS 3.5.1



3



HAZARDS DERIVING FROM MECHANICAL PARTS



HAZARDS THAT MAY BE ENCOUNTERED IN THE WORK AREA Personnel may risk slipping or falling in the work area or in the surrounding zone during machine operation and maintenance. When installing the machine, make sure sufficient space has been left around the machine to reduce these risks. The passageways and areas around the machine must always be: - free of obstacles (such as step ladders, tools, containers, boxes of material) - clean and dry (immediately remove any drops of oil ) - well lit The operator may be seriously injured, as stated in paragraph 3.1. LIGHTING It is fundamental that the areas surrounding the machine and in particular the work zone are always well lit. Replace any defective elements without delay. Minimum value 300 lux.



3.5.2



HAZARDS THAT MAY BE ENCOUNTERED IN THE ELECTRICAL SYSTEM



The slip pump is controlled from the spray dryer switchboard. SWITCHBOARD: DANGER OF COMING INTO CONTACT WITH LIVE PARTS. The switchboard can be accessed even if power is being supplied to the system. As called for by the EN 60204-1 standard, it can be accessed only with a key or other specific tools. These tools must be given exclusively to authorized personnel who are highly qualified and specially trained to access live parts. WHEN POWER IS BEING SUPPLIED TO THE SWITCHBOARD THE QUALIFIED PERSONNEL WHO HAVE BEEN AUTHORIZED CAN ONLY RESET THE SAFETY EQUIPMENT.



E0004P



WARNING!



Whenever a component either inside or outside the switchboard has to be replaced, the maintenance man must shut off the system with the main switch and padlock it in its open position to prevent it from being started up accidentally.



3-7



138.11.A01 3 3.5.3



Revision 00 Date 04.10.1999



SAFETY EQUIPMENT AND PRECAUTIONS MAINTENANCE



The safety measures to be observed while performing maintenance are given in this paragraph. The procedures and any additional safety precautions are given in chapter 8, MAINTENANCE OPERATIONS for each individual job. Make sure the machine is in a safe condition before carrying out any maintenance operations. Once the operations have been completed make sure the machine is able to work safely. In particular make sure all the safety devices and guard interlocks operate properly.



E0004P



WARNING!



Failure to observe these precautions may cause severe personal injury.



E0004P



WARNING!



Do not carry out any repairs or maintenance while the machine is running. Signs must be put up to inform the operators. Before carrying out any operations, disconnect the machine from the power supply by using the main switch. The main switch can also be padlocked in the “power off” position to prevent the machine from being started up accidentally. To ensure top machine performance and proper operation closely follow the instructions provided by the manufacturer and carry out maintenance at the stated intervals. Periodically check all the safety devices for proper operation and the insulation of the power cables. Replace them if damaged. Once maintenance has been completed, check the machine for proper functioning. Most of all make sure all the safety devices are efficient and the guards are in place.



3-8



Revision 00 Date 04.10.1999



138.11.A01



SAFETY EQUIPMENT AND PRECAUTIONS 3.6



3



MAKING THE MACHINE INOPERATIVE



When the machine is no longer to be used, it should be made inoperative by following the instructions given below: - Shut off the electrical power to the machine by using the main switch - Unplug the power cable attached to the terminal block in the electrical cabinet - Unplug the cables between the electrical cabinet and the machine - Disconnect the cooling system from the water supply and factory drain system - Thoroughly clean the entire machine, especially the moving parts, lubricate the parts to protect them - Close the doors of the electrical cabinet and the machine guards to prevent damage, build-ups of dust, etc... - Use any safety devices provided. For information on how to dismantle the machine see chapter 9 DECOMMISSIONING.



3-9



138.11.A01 3



3 - 10



Revision 00 Date 04.10.1999



SAFETY EQUIPMENT AND PRECAUTIONS



Revision 00 Date 04.10.1999



138.11.A01 INSTALLATION



4



INSTALLATION



4.1



LIFTING AND HANDLING



4



SUBDIVISION OF THE MACHINE The machine is divided into two parts: the casing and the hydraulic power unit. DIMENSIONS AND WEIGHTS The weights and measurements refer to each single parts: see paragraph 2.3.1 SPECIFICATIONS. LIFTING EQUIPMENT The points for lifting and transporting the parts are shown in figure 4.1. To lift the packed parts, use suitable equipment and observe all safety precautions. Use maximum care when handling the crates both indoors and outdoors. Always use equipment adequate for the weight of the crate. On arrival, it is fundamental that the all the parts are precisely weighed.



E0004P



WARNING!



The manufacturer shall not be held responsible for injury to persons or damage to equipment that are caused by failure to observe current safety precautions regarding lifting and handling material inside the factory.



SAFETY MEASURES TO BE OBSERVED WHEN LIFTING - Sling the machine as shown in figure 4.1. Use slings that are long enough and adequate for weight of the load. - Protect the points where the sling comes into contact with the machine with cardboard or rags. - Gradually move the load until it is stable. - Carefully lift the load and avoid swaying it.



E0004P



WARNING!



The machine can be lifted and handled only by qualified and authorised personnel. It is extremely important that no one is near the load and/or within the range of action of the overhead traveling crane while the machine is being lifted and moved. - closely follow the instructions given in the SAFETY EQUIPMENT AND PRECAUTIONS chapter. - While being handled the load must always be kept perfectly horizontal regardless or the type of equipment used.



4-1



138.11.A01 4



Revision 00 Date 04.10.1999



INSTALLATION



Figure 4.1 - LIFTING AND HANDLING 1 Pump casing 2 Hydraulic power unit



1



2



C1634



4-2



Revision 00 Date 04.10.1999



138.11.A01 INSTALLATION



4.2



4



POSITIONING AND CONNECTING THE PUMP



When installing the equipment, which is to be done according to the plant requirements, keep in mind the pumps cannot take in a fluid that has the indicated specific weight from a depth greater than that indicated in paragraph 2.3.1 - SPECIFICATIONS, even when working at their max. capacity. (see figure 4.2/A) - Place the pump and hydraulic power unit on the foundations prepared beforehand. - Level and secure with the anchor bolts provided. - Install the suction and delivery lines. Make sure the joints and welds are not cracked as air may leak out during operation and the required vacuum may not be created. - Join the ball valve at the suction end (6) to the water supply. Avoid sharp bends as air pockets may be created and as a result the pump may not be able to take in the fluid. - Connect the HD30 power unit cooler to the water supply. This is also used to flush HD31 porcelain pistons. - Connect the cables to the electrical boxes (1 and 2). - Install the hoses between the assembly (3) of the hydraulic power unit and the pump cylinders (4). Join points A and B of the pump to points A and B of the power unit respectively. - Wire up the electrical box of the hydraulic power unit (1) as well as the electrical box (2) for the pump as shown in diagrams 2.4.4 and 2.4.5. - Ground the machine (see figure 4.2/C). - Remove the paint from the points of contact on the machine for the ground conductors before tightening the related screws so as to ensure good electrical continuity.



E0004P



WARNING!



The equipment is to be connected to the ground electrodes provided.



The points of connection on the equipment are marked with the international ground symbol: E0006



Failure to ground the equipment may cause serious personal injury and property damage.



E0004P



WARNING!



The equipment is to be connected by qualified personnel as indicated by SACMI.



E0004P



WARNING!



The RST cable is not supplied with the machine. Its characteristics and dimensions are given in paragraph 2.3.1 SPECIFICATIONS.



4-3



138.11.A01 4



Revision 00 Date 04.10.1999



INSTALLATION



Figure 4.2/A - POINTS OF USE AND INSTALLATION DIAGRAM 1 2 3 4 5 6 A-B HD30 HD31



3



Electrical box, Hydraulic power unit Electrical box, Pump Control assembly, Hydraulic power unit Pump cylinders Delivery line Suction line Connecting hoses Inlet and outlet fittings, Cooling water for hydraulic power unit Connection, Piston flushing water



B



A 5 HD31



HD31



2 B 4



A



1 HD30



6



4-4



C1640



138.11.A01



Revision 00 Date 04.10.1999



INSTALLATION



4



(See figure 4.2/B) Ball valves should be fitted to both the delivery (13) and suction lines (12) of the machine so that the latter can be shut off without affecting the rest of the system, thereby allowing maintenance to be carried out without stopping the spray drying plant.



Figure 4.2/B - DELIVERY AND INTAKE VALVES



9



1 2 3 4 5 6 7



3



Delivery valve Cover Clamp Plate Intake valve Disk Pin bush



8 Valve seat 9 Guide pin 10 Spring 11 Protective frame 12 Valve on suction line 13 Valve on delivery line 14 Ball valve on suction line 15 Ball valve on delivery line



2 11 10 4 7



6



8



14



5



13



12 1



15



C1642



4-5



138.11.A01 4



Revision 00 Date 04.10.1999



INSTALLATION



Figure 4.2/C - GROUND CONNECTIONS



E0006



C1633



E0006



4-6



Revision 00 Date 04.10.1999



138.11.A01 START UP



5



START UP



5.1



GENERAL INFORMATION



E0004P



5



WARNING!



These operations are to be carried out only by the manufacturer’s personnel who are responsible for starting up the equipment as specified in chapter 1 GENERAL INFORMATION. Hazardous situations may be created causing serious injury to persons and/or damage to equipment if these operations are performed by anyone other than the manufacturer’s staff. For information regarding the control keys, see chapter 6 OPERATING INSTRUCTIONS. First time start up requires specialized mechanics and electricians. The customer’s operator and maintenance staff only have to see how the machine is started up (as it is useful to understand the operating principle of the machine, how to adjust the auxiliary equipment and accessories as well as the safety guards and devices employed) and the trials run to see if the parts have been properly set.



5.2



PRELIMINARY CHECKS



CONDITIONS The machine has already been tested when delivered therefore the machine only needs to be checked for any damage that might have occurred during shipment or installation. - Make sure the max. pressure in the relief valve 115 bar for the PPB 313 or 80 bar for the PPB 308.



5-1



138.11.A01 5



Revision 00 Date 04.10.1999



START UP



PREPARATION (for the references see figure 5.2) - Circulate the cooling water for the hydraulic power unit as well as the water for flushing the porcelain pistons.



WARNING!



E0004P



Never start the pumps without water for washing the pistons as the seals will be prematurely worn and irreparably damaged. - Fill the pump with water to facilitate priming. - After shutting the valves (12 and 13), open the ball valves (14 and 15) located on the fittings of the suction and delivery lines respectively. As a result, the water will flow through the pump casing. - Close the ball valve (15) on the delivery side and the ball valve (14) at the suction end in the order given. As a result, the pump casing will remain full of water. - Open the valves (12 and 13). Figure 5.2 - DELIVERY AND INTAKE VALVES



9



1 2 3 4 5 6 7



3



Delivery valve Cover Clamp Plate Intake valve Disk Pin bush



8 Valve seat 9 Guide pin 10 Spring 11 Protective frames 12 Valve on suction line 13 Valve on delivery line 14 Ball valve on suction line 15 Ball valve on delivery line



2 11



10 4 7



6



8



14



5



13



12 1



15



C1642



5-2



Revision 00 Date 04.10.1999



138.11.A01



OPERATING INSTRUCTIONS 6



6



OPERATING INSTRUCTIONS



E0004P



WARNING!



The directions given in this manual must be closely followed and all safety precautions fully observed.



6.1



CONTROL DEVICES



These devices are located on the spray dryer control panel.



6.2



STARTING AND STOPPING THE EQUIPMENT



6.2.1



START UP PROCEDURE



Before starting the machine make sure all the safety devices (which may have been removed during maintenance) are correctly installed. Check the inflating pressure in the slip accumulator ( the values are indicated in paragraph 2.3.1 SPECIFICATIONS) and make sure the pressure control valve is completely open. Make sure the reverse and timing sensors are placed in such a way as to fully exploit the stroke of the pistons (the reversals are reduced and therefore system performance is improved). When the equipment is started up for the first time or after maintenance has been performed on the hydraulic pump, fill the suction hose of the pump with oil before starting the electric motor. Once the motor has been started up, bleed any air from the delivery hose of the pump. The electric motor can now be started. The entire flow is delivered by the hydraulic pump but the cylinders do not operate as there is hardly any pressure in the circuit. Gradually adjust the control valve. In fact, as a result of slight increases in the oil pressure the alumina pistons accelerate significantly as the duct that joins the pump to the point of use is still empty. Once the line is full, the pressure of the fluid will start to increase and the pump will slow down. The pressure can now be gradually increased until the required value is reached. In versions equipped with a proportional pressure control the start-up ramp and operating pressure control are controlled from the ATM’s electrical cabinet. The operating pressure of the hydraulic circuit is strictly related to the pressure of the slip circuit. For this reason, if the pressure in the hydraulic circuit does not rise neither will the pressure in the slip circuit. The pressure ratio in the PPB 313 is 3.5:1. For example, in order to obtain a pressure of 30 bar in the slip lines, the oil pressure must be about 105 bar. The pressure ratio in the PPB 308 is 2.5:1. or example, in order to obtain a pressure of 30 bar in the slip lines, the oil pressure must be about 75 bar. This ratio is however approximate as it is strictly related to the friction created by the working parts of the machine, in particular between the seals and alumina pistons. Reverse motion should be optimised during this stage. To do this, adjust the relative throttles (7) (see figure 6.3). Increasing braking will extend the stroke of the pump pistons, therefore timing sensors SQ1 and SQ2 need to be reset. In addition, be careful not to full extend or retract the hydraulic cylinders. At this point, the machine will run at normal speed. Check the pressures in the two lines. The pressure gauge (3) should be shut off by using the cock (2). This prevents malfunctioning due to changes in pressure during operation. If the speed of the equipment varies notably due to increased ATM output or one of the pumps has stopped, etc., repeat the adjustments described above in order to suit the new conditions.



6-1



138.11.A01 6 6.2.2



Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS STOPPING THE MACHINE



First of all, gradually relieve the pressure until the equipment stops by using the control valve. Once this has been done, shut off the electric motor with the main controls. At this point, check the pressure gauge located on the slip accumulator to see whether the pressure has dropped. This will ensure that the lines located after the pump are no longer under pressure, thus preventing problems from arising during flushing. The water for flushing the alumina pistons should be shut off after approximately ten minutes. This will ensure that any slip residues are flushed from the washing chambers. The same should be done with the hydraulic unit cooling water. In addition, it is good practice to flush the delivery and intake valves of the pump. To do this, use the valves located on the inlet and outlet fittings of the machine. If good results are not obtained, take off the protective frame and covers of the valves and wash by spraying water.



6.3



OPERATION



(references given in figure 6.3) The gear pump (14), which is driven by the electric motor (12), provides a constant flow of oil which passes through the hydraulic control assembly and is alternately delivered to the upper chambers of the hydraulic cylinders (22). As a result, the cylinders move down. One of the cylinders will move up while one of the pistons goes down, as the two lower chamber are connected to each other. The operating pressure is obtained by setting the control valve (10), which gives the element (9) the pressure at which it has to drain the excess oil. A second pressure level, which is slightly higher than the first one, is obtained through the pressure relief valve (11). The latter comes into operation if the control valve (10) fails to work. The order of operation of the cylinders is defined by the reversing valve (6). The latter is operated by the solenoid valve (8) which receives the pulses for reversing from sensors SQ3 and SQ4. The position of the sensors determines the extent of the stroke. The speed at which the spool of valve (6) reverses motion can be varied by adjusting the throttles (7). As a result, any pressure variations created during this stage will be kept to a minimum. The accumulator (5) can also reduce pressure peaks. The oil pressure is controlled by the pressure gauge (3), which is turned on by opening the cock (2). The check valve (1) is installed in the hydraulic control assembly which protects the pump (14) from abrupt changes in pressure. The equipment also includes a tube bundle heat exchanger (19), suction and drain filters (16 & 17) and a thermometer with switch (21) which reads the oil temperature. When the temperature is too high the electric motor stops running. Note that a level indicator (20) is located outside the reservoir (18).



6-2



138.11.A01



Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS



6



Figure 6.3 - OPERATION 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16



Check valve Cock and pressure gauge Pressure gauge Accumulator Reversing valve Reversing throttles Pilot solenoid valve YV3 - YV4 Filter element Pressure control valve Pressure relief valve Electric motor Coupling Gear pump Check valve Suction filter



17 18 19 20 21 22 23 24



Drain filter Tank Cooler Level indicator with thermometer Thermometer Hydraulic cylinders Timing solenoid valve YV1 Solenoid valve YV2, Upstroke chamber loading SQ Sensors Hydraulic circuit Pilot circuit



23 YV1 A



B



YV2



22



22 24



SQ1



SQ4



A



B



P



T



7



SQ2



SQ3



6



7 A



B



YV4 P



T



8



5 3



YV3



2 1 P T



12



13



14



9



21 10



11



20 19



15 16



17



H2O



18 C0867



6-3



138.11.A01 6 6.4



Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS TIMING



(references given in figure 6.4) During machine operation oil leaks are present in the upper chamber of the cylinders (22) (at high pressure) which tend to increase the volume of oil in the lower chambers (at low pressure). These leaks would cause the machine to stop running as the left-hand cylinder (22) would reach its upper most position before the right-hand one reaches sensor SQ3. As a result the valve (6) would not receive the pulse for reversal. To solve this problem, the timing valve (23) is installed between the reservoir and the upstroke circuit. This valve is piloted by sensor SQ1 which drains the oil from the lower chambers while the left-hand piston keeps SQ1 activated. During this stage the left-hand piston stays in its upper most position while the right-hand one continues to move down until the relative piston activates sensor SQ3 and reversal starts. Under normal operating conditions, the right-hand piston has to reach SQ3 before the left-hand one activates SQ1 so that the latter comes into action only if oil leaks are really present and not during each reversal.



6-4



138.11.A01



Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS



6



Figure 6.4 - TIMING 1 2 3 5 6 7 8 9 10 11 12 13 14



Check valve Cock and pressure gauge Pressure gauge Accumulator Reversing valve Reversing throttles Pilot solenoid valve YV3 - YV4 Filter element Pressure control valve Pressure relief valve Electric motor Coupling Gear pump



15 Check valve 16 Suction filter 17 Drain filter 18 Reservoir 19 Cooler 20 Level indicator 21 Thermometer with switch 22 Hydraulic cylinders 23 Timing solenoid valve YV1 24 Solenoid valve YV2, Upstroke chamber loading SQ Sensors Hydraulic circuit Sections of circuit under pressure Pilot circuit



23 YV1 A



B



YV2



22



22 24



SQ1



SQ4



A



B



P



T



7



SQ2



SQ3



6



7 A



B



YV4 P



T



8



5 3



YV3



2 1 P T



12



13



14



9



21 10



11



20 19



15 16



17



H2O



18 C1011



6-5



138.11.A01 6 6.5



Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS FIRST TIME START UP



(references given in figure 6.5) When the machine is started up for the first time, i.e. when the lower chambers of the cylinders (22) are either empty or almost empty (see figure 6.5), a problem opposite to that described in paragraph 6.4 will arise. The left-hand piston moves fully down before the right-hand slide reaches SQ4 and therefore the valve (6) does not reverse the flow of fluid. The problem can be solved through the use of the charge valve (24). In fact the latter, which is piloted by sensor SQ2, provides a link between the upper chamber of the left-hand cylinder (under pressure during this stage) and the lower chambers. At this point, the left-hand piston remains fully down as both chambers are under pressure while the righthand one moves up until SQ4 is activated causing reverse motion. The valve (24) must not come into action and SQ4 should be activated slightly before SQ2. In addition, keep in mind that the delay time for timing sensors SQ1 and SQ2 in relation to the reversing sensors SQ3 and SQ4 varies depending on the speed of the machine and on how the reversing throttles (7) are set .



6-6



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Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS



6



Figure 6.5 - FIRST-TIME START UP 1 2 3 5 6 7 8 9 10 11 12 13 14 15



16 17 18 19 20 21 22 23 24



Suction filter Drain filter Reservoir Cooler Level indicator Thermometer with switch Hydraulic cylinders Timing valve YV1 Solenoid valve YV2, Upstroke chamber loading SQ Sensors



Check valve Cock and pressure gauge Pressure gauge Accumulator Reversing valve Reversing throttles Pilot solenoid valve YV3 - YV4 Filter element Pressure control valve Pressure relief valve Electric motor Coupling Gear pump Check valve



Hydraulic circuit Sections of circuit under pressure Pilot circuit



23 YV1 A



B



YV2



22



22 24



SQ1



SQ4



A



B



P



T



7



SQ2



SQ3



6



7 A



B



YV4 P



T



8



5 3



YV3



2 1 P T



12



13



14



9



21 10



11



20 19



15 16



17



H2O



18 C1012



6-7



138.11.A01 6



6-8



Revision 00 Date 04.10.1999



OPERATING INSTRUCTIONS



Revision 00 Date 04.10.1999



138.11.A01 ADJUSTMENTS



7



7



ADJUSTMENTS



E0004P



WARNING!



The operations are to be carried out with the machine off and following all the safety precautions dealt with at the beginning of the manual. Always shut off the electrical power to the machine before accessing the electrical cabinet, electrical boxes and wherever “danger-of-electrocution” signs are located. The adjustments described below are to be carried out when necessary in the presence of malfunctioning or after maintenance has been performed, parts replaced, etc.. Carefully observe all the safety precautions when carrying out these operations. Figure 7.1/A



7.1



MACHINE ADJUSTMENTS DURING OPERATION



1



ADJUSTING THE SLIP PRESSURE (references given in figure 7.1/A) The slip spray nozzles are subject to wear. As a result, the output and operating speed of the pumps which supply a spray dryer that has run for several consecutive days may increase (even slightly). This will cause the slip pressure to decrease; to correct , adjust the control valve (1).



C1635



Figure 7.1/B ADJUSTING THE SEALS (references given in figure 7.1/B) The seals (2) may need to be adjusted during operation. Every day, check for slip leakage and, when required, adjust the preload device (1).



1 2



C1643



7-1



138.11.A01 7



7-2



ADJUSTMENTS



Revision 00 Date 04.10.1999



Revision 00 Date 04.10.1999



138.11.A01



MAINTENANCE OPERATIONS 8



8



MAINTENANCE OPERATIONS



GENERAL INFORMATION AND SAFETY PRECAUTIONS



E0004P



WARNING!



Only expert personnel who know how the machine and plant operate should carry out maintenance, as indicated in chapter 3 - “SAFETY EQUIPMENT AND PRECAUTIONS”. Take all the precautions required in order to prevent accidental machine start-up. - turn the main switch on the board to OFF - remove the safety key - post a “maintenance in progress” sign on the electrical cabinet. - press the emergency stop buttons Always keep in mind that risks may arise and follow the safety rules given in chapter 3 - “SAFETY EQUIPMENT AND PRECAUTIONS”.



Maintenance operations are divided as follows: - routine maintenance (to be carried out by the customer’s maintenance staff) - special maintenance (to be carried out either by the manufacturer’s or customer’s specially trained personnel). Routine maintenance includes: - mechanical jobs: lubricating and cleaning mechanical parts, replacing and tensioning the belts, replacing and cleaning the valves, etc.. - electric jobs: replacing fuses in the electrical cabinet. All the maintenance operations must be carried out with the machine stopped and cooled down. Maintenance operations must be carried out at the stated intervals. The operations are divided as follows: - SCHEDULED OPERATIONS; - SPECIAL MAINTENANCE.



8-1



138.11.A01 8



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS



8.1



SCHEDULED MAINTENANCE OPERATION OPERAZIONI



8 CONTROLLO TENUTA SEALS GUARNIZIONI IN GOMMA 1 -- CHECK THE RUBBER PULIZIATHE POMPA E CENTRALINA 2 -- CLEAN PUMP AND HYDRAULIC POWER UNIT LAVAGGIO E TUBAZIONI 3 -- WASH THE VALVOLE VALVES AND PIPING VERIFICA PRESSIONE ACCUMULATORE 4 -- CHECK SLIP ACCUMULATOR PRESSUREBARBOTTINA LUBRIFICAZIONE COLONNE DI GUIDA 5 -- LUBRICATE THE GUIDE COLUMNS SOSTITUZIONE FILTRO ASPIRAZIONE 6 -- CLEAN THE SUCTION FILTER PULIZIATHE SCAMBIATORE DI CALORE 7 -- CLEAN HEAT EXCHANGER VERIFICA PRESSIONE ACCUMULATORE OLEODINAMICO 8 -- CHECK THE HYDRAULIC ACCUMULATOR PRESSURE SOSTITUZIONE OLIO IMPIANTO OLEODINAMICO 9 -- CHANGE THE OIL IN THE HYDRAULIC SYSTEM SOSTITUZIONE FILTRO SCARICO 10 -- CHANGE THE DRAIN FILTER



IN THEREAFTER SEGUITO EVERY OGNI: (HOURS) 2500



TO BE PERFORMED DA ESEGUIRE DOPO ORE: …HOURS



40



200



8 hours ore 8 hours ore 40 hours ore ore 40 hours ore 200 hours 2500 hours ore 2500 2500 hours ore 2500 2500 hours ore 2500 2500 hours ore 2500 2500 hours ore 2500



C1644



1



Checking the rubber seals



(references given in figures 8.1/A and 8.1/A2) Check the water flowing out of the pump washing chambers at the start of every work shift. When under normal working conditions a small amount of slip should come out as it acts as a natural lubricant for the seals. If the amount of slip flowing out increases, adjust the device (1) to increase the pre-load on the seals (3). Carry this out gradually. The seals should be tightened as little as possible. This is extremely important in order not to increase friction and energy dissipation as well as to notably extend the service life of the seals. Ring-nut adjustment (fig. 8.1/A1) The adjustment is to be made gradually. Move the device (1) by half a turn and wait a few minutes to see the results obtained. Use the pin wrenches provided to turn the ring nut (1). Insert the wrenches through the slots in the front and rear boards. The ring nut should be washed with a jet of water before being turned to avoid seizure due to solid particles that may deposit between the threads. If a ring nut (1) is blocked and cannot be turned with the wrench, stop the machine, take off the protective boards and loosen the four screws that secure the ring (2) to the pump casing. After doing this, turn the ring nut (1) counter-clockwise until it can move freely again. Put the parts back in place, pre-load the seals as required and then start the machine again. Stay bolt adjustment (fig. 8.1/A2) In this case, the seals (3) are pre-loaded by turning the nuts (9) which push the plate (1) against the seals. It is essential to tighten the nuts to the same degree so as to pre-load the seals in a uniform manner. The service life of the seals is strictly related to the way this operation is carried out.



E0004P



WARNING!



Only the pin wrenches provided with the machine can be put through the slots in the boards. Never put your hands through them. This is of vital importance.



8-2



138.11.A01



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS



8



1 2 1 2



3



4



4 5



5



8



C 7 A



B



6 7 6 Figure 8.1/A1 - INSTALLING THE SEALS AND PUMP CASING 1 2 3 4 5 6 7 8



Ring nut Ring Seal pack Piston Pump casing Spacer Seal Device for installing seals



A



B



C1013



8-3



138.11.A01 8



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS



1 2



9 1 2 3



4



4 5



5



8



C



7 Figure 8.1/A2 - INSTALLING THE SEALS AND PUMP CASING 1 2 3 4 5 6 7 8 9



Pressure plate Stay bolt Seal pack Piston Pump casing Ring spacer Seal Device for installing seals Nut



B



6



A



7 6



A



B



C1341



2



Cleaning the pump and hydraulic power unit



The hydraulic power unit can be cleaned by blowing compressed air and using rags. This should be done to ensure that the electric motor cools down well and to prevent matter from building up on the cover of the unit, which if parts are removed, may get inside the reservoir and dirty the oil. Running water can be used for the pump to remove any dust or slip build ups that tend to block the ring nut and reduce the sensitivity of the reversal and timing sensors.



8-4



138.11.A01



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS



8



3 Washing the valves and piping (references given in figure 8.1/B) This operation is normally carried out at the end of each work shift or when the material being handled is changed. Shut the pump off from the rest of the system by using the main ball valves located before and after the machine. This should be done after the machine has been stopped and any remaining pressure has been eliminated (check there is no pressure by observing the relevant gauge). Once this has been done, open the ball valves on the delivery and suction lines so that water can flow through the pump, thereby flushing the casing and the plate-type valves. From time to time, thoroughly clean the entire system in the following way. Take off the protective frame, covers and plates of the valves and wash the valve seats and the inside of the pump with jets of water coming from the delivery valve. As a result, the fluid flows through the pumping chamber and out of the intake valve. After checking the seals and seats for condition, wash the bodies of the valve, prime the pump and put everything back in place.



Figure 8.1/B - DELIVERY AND INTAKE VALVES



9



1 2 3 4 5 6 7



3



Delivery valve Cover Clamp Plate Intake valve Disk Pin bush



8 Valve seat 9 Guide pin 10 Spring 11 Protective frames 12 Valve on suction line 13 Valve on delivery line 14 Ball valve on suction line 15 Ball valve on delivery line



2 11



10 4 7



6



8



14



5



13



12 1



15



C1642



8-5



138.11.A01 8 4



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS Checking the slip accumulator pressure (OPT)



At the end of each work shift, make sure the pre-charge pressure has not decreased (the value is indicated in paragraph 2.3.1 - SPECIFICATIONS). If the pressure has dropped, find out what is causing the nitrogen to leak. 5



Lubricating the guide columns



A certain amount of fresh grease (see paragraph 2.3.3, LUBRICANT SPECIFICATIONS) should be injected through the fittings on the guide columns to remove the fine abrasive powders captured by the grease during operation. Take off the front protective board to carry out this operation. 6



Cleaning the suction filter



(references given in figure 8.1/C) The filter in question is installed on the hydraulic pump’s intake line inside the reservoir.



Figure 8.1/C - HYDRAULIC POWER UNIT 1 2 3 4 5 6 7 8



Reservoir Heat exchanger Motor-pump unit Oil thermostat Reservoir filler Suction filter Hydraulic control assembly Drain filter



5



7



3



4



8



1



C1637



6



2 8-6



Revision 00 Date 04.10.1999



138.11.A01



MAINTENANCE OPERATIONS 7



8



Cleaning the heat exchanger



Clean the heat exchanger inside using de-scaling products. 8



Checking the hydraulic accumulator pressure



Install the inflator- tester to check the nitrogen pressure. It should be about 60-70% of the flow pressure. If the value read is lower, inflate the bag with a full nitrogen cylinder. 9



Changing the oil in the hydraulic system



(references given in figure 8.1/C) This operation is extremely delicate as, if it is not correctly carried out, the oil will be highly contaminated shortening the service life of all the hydraulic components, above all the filters and solenoid valves. Thoroughly clean the hydraulic power unit, completely empty the reservoir by using the drain plug located on the bottom, wash the reservoir inside with oil and then fill it up. Use hydraulic oil that meets the specifications indicated in paragraph 2.3.3, Lubricants. Add oil through the filler (5), if required. 10 Changing the drain filter (references given in figure 8.1/C) The filter (8) in question is located outside the reservoir of hydraulic power unit. When the indicator located on the filter constantly reads 2 bar, replace the filter cartridge even if the time interval indicated in the scheduled maintenance chart has not elapsed.



8-7



138.11.A01 8 8.2



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS SPECIAL MAINTENANCE



The special maintenance operations that usually regard only the machine in question are described below. 8.2.1 REPLACING THE RUBBER SEALS (references given in figure 8.1/A) IMPORTANT! When the ring nut or plate (1) is almost all the way down the whole seal pack (3) has to be replaced. The alumina piston will wear down much more quickly if overworn seals are used. For this reason, the ring nut should be replaced when the piston only completes 2/3 of its total stroke. -



Move the piston (4) fully up Completely loosen the pressing system Raise the ring nut or plate as far up as possible Remove the seal pack (3) (seals 7 and spacers 6) Thoroughly clean the chamber Install the new seal pack moistening it with a silicone based lubricant which eases the operation and decreases friction between the seals and the mechanical parts (piston and cylinder).



IMPORTANT! The seals (7), when supplied, have the correct length and adequate contact surfaces. The spacers (6) have to be cut in slices. Insertion is made easier if the clamp (8) provided with the machine is used. Do not overlap points (A) of the seals over those of the clamp (B) to avoid oil leaks. - Put a spacer (6) (cut so that it fits around the piston 4) in the seat of the cylinder (5). Push it all the way down. - Put a seal (7) around the piston (4), being very careful to accurately join the ends together and fit it into the seat of the cylinder (5). - Fit the clamp (8) over the piston (4) and push it downwards to lower the seal. Make sure that the seal is in place before pushing the clamp down. Also ensure the joints of the clamp do not match those of the seals. - Remove the clamp (8) and take it apart. - Put on another cut ring spacer (6). - Install another seal (7) by performing the procedure described above and continue until the entire pack (3) has been installed. RING-NUT ADJUSTMENT - Hold the ring (2) in place by slightly tightening the respective screws. - Tighten the ring nut (1) until it rests on the seal pack - Secure the ring (2). STAY-BOLT ADJUSTMENT - Turn the nuts (9) of the stay bolts (2) to bring the plate (1) into contact with the seal pack. - Slightly pre-load with the nuts (approx. half a turn). WARNING! To further preload the seal pack (3), turn the ring nut (1, figure 8.1/A1) or the stay bolts of the plate (1, figure 8.1/A2). This operation is to be performed with the pump running only if required.



8-8



Revision 00 Date 04.10.1999



138.11.A01



MAINTENANCE OPERATIONS



8



8.2.2 OVERHAULING THE DELIVERY AND INTAKE VALVES (references given in figure 8.1/B) The disk (6) and valve seat (8) get worn when slip under pressure flows in the intake valves. These parts therefore need to be replaced. - Take off the protective frames (11) - Replace the parts (6 and 8) - Put the parts back in their correct position and tighten the clamp (3) - Put the protective frames (11) back on.



8-9



138.11.A01 8



Revision 00 Date 04.10.1999



MAINTENANCE OPERATIONS



8.3



CHECKING THE NUTS AND BOLTS FOR TIGHTNESS



Sr = Resisting section (mm2) M = Tightening torque (N.m) P = Pre-load (corresponding to the tightening torque) (N).



NOTE: Class 12.9 screws must be tightened with a torque wrench as if they were class 10.9.



Example: a 12 mm diameter screw, 1.75 thread, 12.9 must be tightened to 12.28 Kg instead of 14.74 Kg.



COARSE THREAD SCREWS



DIAMETER



mm.



4



5



6



8



10



12



14



16



18



20



22



24



27



30



36



PITCH



mm



0.70



0.80



1.00



1.25



1.50



1.75



2.00



2.00



2.50



2.50



2.50



3



3



3,5



4



Sr



mm2



8.78



14,2



20,1



36,6



58



84,3



115



157



192



245



303



353



459



561



817



M (Nm)



1,9



3,8



6,5



15,4



31,3



53



84,3



128



177



250



332



432



631



857



1500



2500



4000



5600



10250



16200



23600



32200



68600



84800



98800



3,1



6



10,4



24,6



50,1



84,8



135



400



532



691



3930



6360



9000



16400



26000



37800



51500



4,3



8,5



14,6



34,7



70,5



119



190



5530



8950



12700



23100



36500



53000



72500



5,2



10,1



17,5



41,6



84,6



143



228



6640



10700



15200



27740



43900



63700



86900



5.8



P (N)



CLASS



8.8



M (Nm) P (N)



10.9



M (Nm) P (N)



12.9



M (Nm) P (N)



44000 53800 205



283



70300 86000 288



1010



110000 136000 158000



398



562



98900 121000 346



129000 157000 228800



748



971



20600 1420



1370



251000 366000 1930



478



674



119000 145000



897



1170



1700



2310



mm



8



10



12



14



16



18



20



22



24



27



30



36



PITCH



mm



1,00



1,25



1,25



1,50



1,50



1,50



1,50



1,50



2



2



2



3



S.R.



mm2



39,2



61,2



92,1



125



167



216



272



333



384



496



621



865



M (Nm)



16,3



32,7



56,6



89,6



134



193



270



357



457



667



923



1587



11000



17100



25800



35000



46800



60500



76200



93200



108000



139000



174000



242200



26



52,4



90,6



143



214



308



431



571



731



1070



1480



2539



17600



27400



41300



56000



74800



96800



122000



149000



172000



222000



278000



387500



36,6



73,6



127



202



302



434



607



803



1030



1500



2028



3570



24700



38500



58000



78800



105000



136000



171000



210000



242000



312000



391000



544900



43,9



88,4



153



242



362



520



728



964



1230



1800



2490



4284



29600



46300



69600



94500



126000



163000



206000



252000



290000



375000



469000



653900



CLASS



8.8



M (Nm) P (N)



10.9



M (Nm) P (N)



12.9



M (Nm) P (N)



8 - 10



4046



185000 229000 267000 347000 424000 617600



DIAMETER



P (N)



3372



154000 191000 222000 289000 353000 514700



FINE THREAD SCREWS



5.8



2398



Revision 00 Date 04.10.1999



138.11.A01 DECOMMISSIONING



9



9



DECOMMISSIONING



Proceed as follows to dismantle the machine: - disconnect the machine from the electricity supply. - disassemble the various parts observing all safety precautions and following the instructions given in chapter 4 INSTALLATION.



9-1



138.11.A01 9



9-2



DECOMMISSIONING



Revision 00 Date 04.10.1999